Rapid Synthesis of Poly(methyl methacrylate) Particles with High Molecular Weight by Soap-Free Emulsion Polymerization Using Water-in-Oil Slug Flow

A flow process for the production of poly(methyl methacrylate) (PMMA) particles is proposed by soap-free emulsion polymerization using a water-in-oil (W/O) slug flow in a microreactor. Thin oil films generated around the dispersed aqueous phase of the W/O slug prevent the prepared particles from adhesion to the microchannel wall, enabling the continuous production of PMMA particles without clogging. The effects of the linear flow rate of the slug flow and the addition of ethanol in the dispersed aqueous phase on the polymerization are evaluated. It is found that increasing the linear flow rate of the slug flow or the addition of ethanol in the dispersed aqueous phase results in PMMA particles with high molecular weight (≈1500 kg mol ⁻¹ ) in 20 min reaction time. It is believed that this process would be a promising way to prepare polymer particles with high molecular weight in a short reaction time.